Mobile vehicle sensor array

ABSTRACT

An improved sensor array for a mobile vehicle. More particularly, the primary objective of the present invention is to provide mobile vehicle ( 10 ) traveling in a forward direction with a sensor array ( 12 ). Sensor array ( 12 ) comprises a first sensor ( 16 ) mounted to mobile vehicle ( 10 ) at a maximum lateral distance from said vertical axis of rotation ( 21 ) near a first side of mobile vehicle ( 10 ) and a second sensor ( 18 ) mounted to mobile vehicle ( 10 ) at a maximum lateral distance from said vertical axis of rotation ( 21 ) near a second side of mobile vehicle ( 10 ). First sensor ( 16 ) and the second sensor ( 18 ) emit object detecting beams for detecting an object ( 39 ) ahead of mobile vehicle ( 10 ). A plurality of other object detecting beams are emitted obliquely to the object detecting beams of sensor ( 16 ) and sensor ( 18 ). These other beams, in conjunction with the object detecting beams from sensor ( 16 ) and sensor ( 18 ) form zones of overlapping beam coverage for better detection of objects.

REFERENCE DOCUMENT

This application is related to the subject matter discussed in Disclosure Document No. 536507 submitted on Aug. 8, 2003, to the Commissioner for Patents entitled “Reconfigurable 195 Degree Sonar Vision with Peripheral Vision.”

TECHNICAL FIELD

This invention relates to a sensor array for a mobile vehicle. More particularly, this invention relates to a sensor array for a mobile vehicle traveling in a forward direction having a first sensor and a second sensor. The first sensor is disposed on the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near a first side. The second sensor is disposed on the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near a second side. The first sensor emits a first object detecting beam ahead of the mobile object. The second sensor emits a second object detecting beam ahead of the mobile object. The first object detecting beam overlaps with other obliquely emitted object detecting beams from a plurality of sensors on a front of the mobile vehicle to create an overlapping beam coverage to detect object in the path of the mobile vehicle. The second object detecting beam overlaps with other obliquely emitted object detecting beams from a plurality of sensors sensor to create an overlapping beam coverage to detect objects in the path of the mobile vehicle.

BACKGROUND ART

Control systems for a mobile vehicle need to accurately detect when an object is on a collision course with the mobile vehicle. For example, the mobile vehicle may be an unmanned, robotic cleaning machine. Prior art robotic cleaning machines have problems detecting objects directly ahead of the cleaning machine because sensors mounted on the cleaning machine emit beams that don't accurately detect the presence of an object directly ahead of the left forward and the right forward edges of the cleaning machine. Further, prior art cleaning machines have a limited field of vision because the sensors don't accurately detect an object's location ahead of a cleaning machine. Other problems with prior art cleaning machines include that the mobile vehicle transmits beams that interfere with the received beams so that is it difficult to detect objects close to the cleaning machines, and these mobile vehicles have limited built-in redundancy for detecting objects directly in the path of the cleaning machines.

As such, there is a need for an improved control system for the mobile vehicle, which improves the mobile vehicle's detection of the objects directly ahead of the mobile vehicle left and right forward edges, and provides other advantages over prior art cleaning machines such as reduced interference between transmitted beams from the mobile vehicle and received beams widths from the objects. Still other advantages include the mobile vehicle's improved transmitted beam patterns so that the mobile vehicle detects accurately the distance between the cleaning machine and the structures it approaches, i.e., walls, and/or objects located directly in front the mobile vehicle and at the periphery of the sides of the mobile vehicle.

DISCLOSURE OF THE INVENTION

Accordingly, the primary objective of the present invention is to provide an improved sensor array for a mobile vehicle. More specifically, the present invention is a sensor array for a mobile vehicle that travels in a forward direction, which mobile vehicle has a front, a first side, a second side and a vertical axis of rotation. The sensor array includes a plurality of sensors disposed generally along said front of said mobile vehicle emitting a plurality of object detecting beams. The sensor array comprises a first sensor and a second sensor. A first sensor is disposed on the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near the first side for emitting a first object detecting beam. A second sensor is disposed on the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near the second side for emitting a second object detecting beam. As such, the first object detecting beam and the second object detecting beam detect objects ahead of the mobile vehicle.

Another feature of the present invention is that the sensor array includes recessing the sensors to provide better detection of an object. Specifically, in one preferred embodiment of the present invention the sensor array for the mobile vehicle has the first sensor recess-mounted within a periphery of the mobile vehicle. Further, the second sensor is recess-mounted within a periphery of the mobile vehicle. A sensor array for said mobile vehicle wherein said first sensor and said second sensor mounting further includes recessing at least one of said first sensor and said second sensor within a periphery of said mobile vehicle. In one preferred embodiment, a sensor array for said mobile vehicle further comprises a third sensor, which said third sensor is disposed in said mobile vehicle adjacent to said first sensor, obliquely emits a third object detecting beam that overlaps with said first object detecting beam to create an overlapping beam zone for detecting objects. In another preferred embodiment, mobile vehicle further comprises a fourth sensor, which said forth sensor is disposed in said mobile vehicle adjacent to said second sensor, obliquely emits a fourth object detecting beam that overlaps with said second object detecting beam to create an overlapping beam zone for detecting objects ahead of said mobile vehicle direction of travel.

To further improve detection of objects, an additional feature of the present invention is that the sensor array has the at least two overlapping beam zones where the data of the object location is computed utilizing sensor fusion software. The fusion software increases a confidence level for detecting the object ahead of the mobile vehicle because as the mobile vehicle travels toward the object, the object is detected in successive multiple overlapping beam zones. Another feature of the present invention is that the first and the second sensors are selected from a group consisting of piezoelectric sensors, electrostatic sensors, magnetorestrictive sensors, infrared sensors and light detecting and ranging (LIDAR) sensors.

Another feature in an alternative preferred embodiment of the present invention is providing impedance tapering for the sensors of the array to increase the accuracy of the detection of objects. Specifically, the sensor array further includes the first sensor recess-mounted within a first acoustically tapered matching network and the second sensor recess-mounted within a second acoustically tapered matching network. In one preferred embodiment of the present invention, the first acoustically tapered impedance matching network comprises a first conically tapered horn and the second acoustically tapered impedance matching network comprises a second conically tapered horn. More specifically in one alternative preferred embodiment of the present invention, the first acoustically tapered impedance matching network comprises a first conically tapered horn, wherein the first conically tapered horn transitions a small piston diameter acoustical beamwidth radiating from the first sensor to a larger piston diameter acoustical beamwidth. More specifically in one alternative preferred embodiment of the present invention, the second acoustically tapered impedance matching network comprises a second conically tapered horn, wherein the second conically tapered horn transitions a small piston diameter acoustical beamwidth radiating from the second sensor to a larger piston diameter acoustical beamwidth.

In one preferred embodiment, a plurality of sensors are asymmetrically spaced-apart sensors that are mounted on the mobile vehicle and that are asymmetrically spaced-apart sensors are not located in the same plane. In another preferred embodiment, a plurality of sensors are symmetrically spaced-apart sensors that are mounted on the mobile vehicle and that all symmetrically spaced-apart sensors are located in the same plane. In this preferred embodiment of the present invention, an engineer may custom position the plurality of sensors to maximize forward area coverage depending on the shape of the mobile vehicle. In one alternative preferred embodiment of the present invention, the spaced-apart sensors comprise sonar sensors each emitting a beamwidth within the range of approximately 12 degrees to approximately 15 degrees. In another preferred embodiment of the present invention, the spaced-apart sensors comprise light emitting and ranging detectors (LIDAR) sensors.

It is another feature of the present invention that the spaced-apart sensors may be arranged in multiple configurations to maximize a field of vision of the mobile vehicle. In particular, in one preferred embodiment of the present invention, the spaced-apart sensors are configured or reconfigured in a U-shape arrangement to achieve an approximate 195-degree field of view for a mobile vehicle comprising a rectangular shape with rounded corners. It is another feature of the present invention, the spaced-apart sensors for the mobile vehicle that are configurable and reconfigurable by a user to suit the shape of the mobile vehicle so that different data coverage areas may be programmed into the sensor array to maximize detection of the objects.

Further, a method for the present invention is disclosed for controlling a direction of travel of a mobile vehicle having a front, a first side, a second side and a vertical axis of rotation traveling in a forward direction comprising mounting a first sensor to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near a first side. Afterwards, mounting a second sensor to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation near a second side. Following, the method further comprises emitting a first object detecting beam from the first sensor ahead of the mobile vehicle, emitting a second object detecting beam from the second sensor ahead of the mobile vehicle and illuminating an object directly ahead of the left forward edge and the right forward edge of the mobile vehicle by one selected from the group consisting of the beam emitted by the first sensor and the beam emitted by the second sensor. In a further step of the present method, the first sensor and the second sensor mounting further includes recessing the first sensor and the second sensor within a periphery of the mobile vehicle.

In an alternative embodiment of the method for controlling the direction of travel of the mobile vehicle further comprises the steps of mounting a third sensor to the mobile vehicle along the front, mounting a fourth sensor to the mobile vehicle on the front to the left of the third sensor, and mounting a fifth sensor to the mobile vehicle on the front to the left of the fourth sensor. Additional steps include the fourth sensor emitting an fourth object detecting beam which forms overlapping beam zone with the first object detecting beam from the first sensor. Another step includes emitting a fifth object detecting beam from the fifth sensor, whereby the fifth object detecting beam from the fifth sensor forms an overlapping beam zone with a first object detecting beam from the first sensor.

Another preferred embodiment of the present method for controlling the direction of travel of the mobile vehicle further comprises the steps of collecting data from the overlapping beam zones about the location of the object, and processing the data using fusion software. In the alternative, the present method further includes the step of mounting spaced-apart sensors along the mobile vehicle to provide more than two overlapping beam zones, wherein the spaced-apart sensors are configurable to provide scanning area coverage selected from a range of approximately 190-degrees to approximately 200-degrees. Another alternative embodiment of the present inventive method further includes the step of mounting a third sensor near a center of the front of the mobile vehicle, whereby the third sensor emits a third object detecting beam comprising a light detecting and ranging (LIDAR) beam at the object in front of the mobile vehicle and at a peripherally located object or a wall.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference is made to the below-referenced accompanying drawings. Reference numbers refer to the same or equivalent parts of the present invention through several figures of the drawings.

FIG. 1 is a sensor array mounted on a mobile vehicle.

FIG. 2A is an illustration of one preferred embodiment of the present invention depicting the front of a rectangular shaped mobile vehicle with rounded corners.

FIG. 2B is an illustration of one preferred embodiment of the present invention depicting the beam pattern and overlapping beams for a rectangular shaped mobile vehicle with rounded corners.

FIGS. 2C, 2D, and 2E are illustrations of the overlapping beam zones, for the FIG. 2A embodiment, created by the spaced apart sensors and the first sensor located at a maximum lateral distance from a vertical axis of rotation near the first side.

FIG. 3A is a top view of an acoustically tapered impedance matching network for one preferred embodiment of the present invention.

FIG. 3B is a side view of the acoustically tapered impedance matching network for one preferred embodiment of the present invention.

FIG. 3C is a perspective view of the acoustically tapered impedance matching network for one preferred embodiment of the present invention.

FIG. 4 is a flow diagram depicting the method whereby the mobile vehicle detects objects.

MODES FOR CARRYING-OUT THE INVENTION

The present invention provides an improved sensor array for a mobile vehicle. Accordingly, the primary objective is to provide an improved sensor array so that the mobile vehicle detects more accurately the location of objects ahead of the mobile vehicle. In particular, the primary objective of the present invention is to provide a mobile vehicle traveling in a forward direction having a front, a first side, a second side and a vertical axis of rotation with improved detection ability of objects ahead of the mobile vehicle.

FIG. 1 is a sensor array mounted on a mobile vehicle. A mobile vehicle 10 comprises a sensor array 12. In one preferred embodiment of the present invention, mobile vehicle 10 is a unmanned cleaning machine for floors. In the alternative, the mobile vehicle may be any automatic or semiautomatic machine that will follow a programmed path with a minimum or no human supervision. In this preferred embodiment, mobile vehicle 10 is traveling in the forward direction. In this preferred embodiment, the forward direction is the Y-direction. Sensor array 12 comprises a plurality of sensors including a first sensor 16 and a second sensor 18. In this preferred embodiment of the present invention, the plurality of sensors further includes sensors 26, 28 and 30 which sensors 26, 28 and 30 are mounted to the mobile vehicle. In the preferred embodiment of the present invention, first sensor 16, second sensor 18, and sensors 26, 28 and 30 are selected from a group consisting of piezoelectric sensors, electrostatic sensors, magnetorestrictive sensors, light detecting and ranging (LIDAR) sensors or the like. Further, first sensor 16 is disposed on mobile vehicle 10 at a maximum lateral distance from vertical axis of rotation 21 near a first side 15. Second sensor 18 is disposed on mobile vehicle 10 at a maximum lateral distance from vertical axis of rotation 21 near a second side 13.

In this preferred embodiment of the present invention, as shown in FIG. 1A, sensor array 12 transmits object detecting beams at an object 20 or at a wall 22. Afterwards, as shown in FIG. 1B, the object detecting beams are reflected off the object 20 or the wall 22. Following, sensor array 12 receives these reflected object detecting beams and uses this information to ascertain position. In this embodiment, first sensor 16 and second sensor 18, as well as other sensors 26, 28 and 30 of sensor array 12 are mounted in the same plane. In one preferred embodiment of the present invention, sensor array 12 plurality of sensors comprises symmetrically spaced-apart sensors that are mounted on the mobile vehicle and are all symmetrically spaced apart and are all located in the same plane. In an alternative embodiment of the present invention, sensor array 12 plurality of sensors comprises asymmetrically spaced-apart sensors that are mounted on the mobile vehicle. In one preferred embodiment, the asymmetrically spaced-apart sensors are not located in the same plane so that an engineer may custom design sensor array 12 to maximize area coverage for a given shape of mobile vehicle 10.

FIG. 2A is an illustration of one preferred embodiment of the present invention depicting a rectangular shaped mobile vehicle with rounded corners. In particular, this preferred embodiment of the present invention has the spaced-apart sensors for a mobile vehicle comprising a rectangular shape with rounded corners are arranged in a U-shape. The spaced-apart sensors are sonar sensors which are in this preferred embodiment of the present invention Polaroid 700 series electrostatic transducers that emit a beamwidth of 15 degrees. In another preferred embodiment of the present invention, the spaced-apart sensors comprise sonar sensors each emitting a beamwidth within the range of approximately 12 degrees to approximately 15 degrees. However, it should be noted that any type of piezoelectric (ceramic) or electrostatic, sensor having beamwidths from four degrees to sixty degrees may be utilized as the sonar sensors in sensor array 12.

In this preferred embodiment, there are fifteen sensors in the sensor array to create the beam pattern coverage with no gaps, thereby providing approximately 195-degrees of data coverage. Specifically, there is a first transducer 37 mounted at the periphery of the sensor array at maximum lateral distance from said vertical axis of rotation near the first side where the first transducer points at zero degrees. Further, there is a second transducer 38 mounted at the periphery of the sensor array at a maximum lateral distance from said vertical axis of rotation near the second side where the second transducer points at zero degrees. There is a third transducer 39 mounted at the center of mobile vehicle 10 at zero degrees to detect objects directly ahead of mobile vehicle 10. Furthermore, there are six transducers positioned at angles relative to zero degrees including a fourth transducer 40 pointing at −15 degrees, a fifth transducer 42 pointing at −30 degrees, a sixth transducer 44 pointing at −45 degrees, a seventh transducer 46 pointing at −60 degrees, an eighth transducer 48 pointing at −90 degrees, and a ninth transducer 45 pointing at −75 degrees.

In addition, there are six transducers positioned from zero degrees including a tenth transducer 50 pointing at +15 degrees, an eleventh transducer 52 pointing at +30 degrees, a twelfth transducer 54 pointing at +45 degrees, a thirteenth transducer 56 pointing at +60 degrees, an fourteenth transducer 58 pointing at +90 degrees, and a fifteenth transducer 60 pointing at +75 degrees. More specifically, the first 37 and the second 38 transducers are preferably situated from each other at zero degrees relative to each other. The fifteen sensors of the preferred embodiment of the present invention have a preferable beamwidth of fifteen degrees, where 7.5 degrees is on each side of the center of a beam. As such, 7.5 degrees on each side of the center of each of the beams creates a 195-degree field of view.

FIG. 2B illustrates the overlapping beam zones for the FIG. 2A preferred embodiment of the present invention. In this preferred embodiment of the present invention, the sensor array includes the first transducer and the second transducer which provide for the detection of objects directly ahead of the left and the right edges of the array. The arrangement of the other transducers, i.e. 40, 42, 44, 46, 48, 45, 50, 52, 54, 56, 58, 60, are mounted to in a fan shaped array to emit an obliquely beam pattern. First transducer 37 and second transducer 38 are further positioned to act in conjunction with the fan shaped array providing at least two overlapping beam zones to provide collision data ahead of the front of the mobile vehicle. In particular, these overlapping beam zones creates a stereo field view for detecting objects directly ahead and at the periphery of the mobile vehicle. In another alternative preferred embodiment of the present invention is that the sensor array includes recessing the sensors to provide better detection of objects and less signal interference.

FIG. 2C is an illustration of the overlapping beam zones, for the FIG. 2A embodiment, created by the spaced apart sensors and the first sensor at a minimum negative X-direction. Specifically, as shown in FIG. 2C, in one preferred embodiment of the present invention, the sensor array for the mobile vehicle detects objects approaching the mobile vehicle within overlapping beam zones. Each succession time the object is seen, there is created a greater confidence level that the mobile vehicle is approaching the object. For example, an object 39, as shown in FIG. 2C having a triangular surfaces, exclusively detected by transducer 37 emitted object detecting beam creates a first confidence level 41 that object 39 is within range of the mobile vehicle. Afterwards, as shown in FIG. 2D, when the mobile vehicle travels closer to object 39, object 39 is detected within a first overlapping beam zone created by the object detecting beam emitted from transducer 40 and the object detecting beam emitted from transducer 37, creating a second confidence level 43 that the mobile vehicle is approaching object 39. Following, as shown in FIG. 2E, when the mobile vehicle travels even closer to object 39, object 39 is detected within a second overlapping beam zone created by the object detecting beam emitted by transducer 42 and the object detecting beam emitted from transducer 37, creating a third confidence level 45 that the mobile vehicle is ready to contact object 39. In summary, this invention utilizes multiple overlapping beam zones where the object is detected to verify that mobile vehicle 10 is approaching the object. Similar to the first transducer mounted near a first side detecting objects, the second transducer will detect objects using overlapping beam coverage with transducers mounted near the second side of the mobile vehicle.

To further improve detection of objects, an additional feature of the present invention is that the sensor fusion software increases the confidence level for detecting objects. The sensor array comprises at least two overlapping beam zones wherein the data is computed through the use of sensor fusion software, whereby a confidence level for detecting the object ahead of the mobile vehicle is increased by the software. Furthermore, this above mentioned transducer arrangement achieve approximately a 195-degree field of vision. It is another feature of the present invention that the spaced-apart sensors may be arranged in multiple configurations to maximize a field of vision of the mobile vehicle. It is another feature of the present invention that the plurality of sensors includes spaced-apart sensors for the mobile vehicle are configurable and reconfigurable by a user so that for different coverage areas, the spaced-apart sensors may be programmed to maximize detection of the object. TABLE 1 Layout Dimensional Data for 195-degree Sensor Array Degrees from Y- Direction Course of Length Angle Transducer Number Motion of the line sensor points 37 (−90) 13.6 0 45 (−84) 13 −75 48 (−76) 12.62 −90 46 (−65) 12 −60 44 (−56) 9.875 −45 42 (−43) 7.625 −30 40 (−23) 6.25 −15 39    0 5.875 0 50   23 6.25 15 52   43 7.625 30 54   46 9.875 45 56   65 12 60 58   76 12.62 90 60   84 13 75 38   90 13.6 0

Table 1 above describes the mounting instructions for the FIG. 2A preferred embodiment to achieve approximately a 195-degree field of vision. The table represents the layout of the sensors into a U-shaped arrangement that would be suitable for a mobile vehicle. All line lengths and angles are measured from a midpoint on a line segment drawn between the two headlight sensors (first transducer 37 and second transducer 38). This table shows the ideal locations for a sensor array to be used on a mobile vehicle that is a cleaning machine such as the Windsor SG28 or the Nilfisk-Advance Advenger that is to be converted into a mobile robot. It should be noted that transducer 46 and 48 may be interchanged if it is desirable to have the ninety degree transducer moved to the extreme forward position of the mobile vehicle. The individual transducers don't all need to be located in the same vertical plane. The individual transducers are ideally situated at zero degrees of a horizontal plane. Other transducers may be tilted forward or reversed as desired for detecting objects such as corners, ledges, stairs, or the like.

In this alternative preferred embodiment of the present invention, the spaced-apart sensors for the mobile vehicle comprising a round shape are arranged in a semi-circular arrangement. In this alternative embodiment of the present invention, the sonar array 12 having a plurality of sensors comprises asymmetrically spaced-apart sensors that are mounted on the mobile vehicle. In this alternative embodiment, the asymmetrically spaced-apart sensors are not located in the same plane. In another alternative embodiment, the asymmetrically spaced-apart sensors are located in the same plane. In yet another alternative the spaced apart sensors may be symmetrically spaced-apart sensors that may or may not be located in the same plane. In this manner, an engineer may custom design the sensor array to maximize area coverage for a given shape of a mobile vehicle.

FIGS. 3A and 3B are respectively a top view of an acoustically tapered impedance matching network and a side view along the A-A section for one preferred embodiment of the present invention. In this alternative embodiment of the present invention, impedance tapering for the sensors of the array increases the detection accuracy of the object. Specifically, as shown in FIG. 3A, a recess-mounted sensor 51 within a first acoustically tapered matching network 53 with a mobile vehicle periphery 56. As shown in FIG. 3B, recess-mounted sensor 51 has a beamwidth 55 that is approximately 15 degrees and the cone 57 has a angle of approximately 30 degrees. In this preferred embodiment of the present invention for minimum reflection of wave energy, angle of the cone 57 is required to be greater than a beamwidth 55. In this preferred embodiment of the present invention the first acoustically tapered impedance matching network comprises an conically tapered horn. By tapering the acoustical wave, transmitted waves from recessed mounted sensor 51 will not reflect back from an intersection of the acoustically tapered impedance matching network and a surface of the mobile object. As such, the transmitted waves will not reflect back to recess mounted sensor 51, causing the received signals to be interfered with or distorted, thereby preventing inaccurate measurements of the object (not shown in the Figure). FIG. 3C displays a perspective view of the recess mounted sensor 51. Other sensors may be recess mounted, such as a second acoustically tapered impedance matching network comprises an conically tapered horn.

Furthermore, recessed-mounted senor 51 will allow the objects closer to the mobile vehicle to be detected more accurately than is possible without recess mounting. For example, the recess-mounted sensor 51 allows the beam with the mobile vehicle to be pointed at a sharper angle, i.e. closer to a periphery of the mobile vehicle, so that when the object gets near to the mobile vehicle, the object is still detectable. In contrast, a surface-mounted sensor (not shown in Figure) emitted a beam with an angle that depends on the periphery of the mobile vehicle. In this preferred embodiment, a recess-mounted sensor mounting angle has more options.

FIG. 4 is a flow diagram depicting the method whereby the mobile vehicle detects objects. In particular, a method for the present invention is disclosed for controlling a direction of travel of a mobile vehicle having a front and a vertical axis of rotation, traveling in a forward direction comprising mounting a first sensor to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation and mounting a second sensor to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation. Afterwards, method includes step 60 emitting an object detecting beam from the first sensor ahead of the mobile vehicle, step 62 emitting an object detecting beam from the second sensor ahead of the mobile vehicle; and step 64 illuminating an object ahead of the mobile vehicle by one selected from the group consisting of the beam from the first sensor and the beam from the second sensor. In an alternative embodiment of the present inventive method, the method further includes recess mounting the first sensor and the second sensor within a periphery of the mobile vehicle.

To increase accuracy of detecting objects, an alternative embodiment of the method is disclosed for controlling the direction of travel of the mobile vehicle further comprising step 66 mounting a third sensor to the mobile vehicle along a center of the front of the mobile vehicle, step 68 mounting a fourth sensor to the mobile vehicle to the left and adjacent to the third sensor. Additional step 70, in an alternative embodiment, includes emitting an object detecting beam from the fourth sensor, whereby the object detecting beam from the fourth sensor forms a first overlapping beam zone with the object detecting beam from the first sensor. Another additional step 72, in another alternative embodiment, includes mounting a fifth sensor to the left and adjacent to the fourth sensor, emitting an object detecting beam from said fifth sensor. The object detecting beam from the fifth intersects with said object detecting beam from said first sensor to create a second overlapping beam zone. These first and second overlapping beam zones being detected in succession creates a increasing confidence level that the mobile vehicle will collide with the mobile vehicle. Similar overlapping beam zones are created with the second sensor and object detecting beams emitted by other transducers.

Another preferred embodiment of the present method for controlling the direction of travel of the mobile vehicle further comprises the steps of collecting data coverage about the location of the object, and processing the data using fusion software. The fusion software increases the confidence of the position of the object ahead of the mobile vehicle. Fusion software allows a user to fuse the recording of the object's position as the mobile vehicle approaches the object using multiple zones of coverage. For example, as the mobile vehicle approaches the object, the object will pass through multiple increasingly closer overlapping beam zones, increasing the confidence level that the mobile vehicle is approaching the object.

As such, this multiple detection by overlapping beam zones allows a user to generate more confidence of the position of the object so that the mobile vehicle can maneuver around it. In other words, the fusion software represents a method of positively identifying the actual position of the object with a high degree of certainty. By fusing the beam data, the computed detection area with be only −1 dB. By comparison, the normal detection of the object would be only −3 dB.

In the alternative, the present method further includes the step of mounting spaced-apart sensors along the mobile vehicle to provide more than two overlapping beam zones, wherein the spaced-apart sensors are configurable to provide scanning area coverage selected from the range of approximately 190-degrees to approximately 200-degrees.

Another alternative embodiment of the present inventive method further includes the step of mounting a third sensor near a center of the front of the mobile vehicle, whereby the third sensor emits a third object detecting beam comprising a light detecting and ranging (LIDAR) beam toward the object in front of the mobile vehicle and toward a peripherally located object or wall.

Information as herein shown and described in detail is fully capable of attaining the above-described object of the invention and the present preferred embodiment of the invention, and is, thus, representative of the subject matter which is broadly contemplated by the present invention. The scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and is to be limited, accordingly, by nothing other than the appended claims, wherein reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment and additional embodiments that are known to those of ordinary skill in the art are hereby expressly incorporated by reference and are intended to be encompassed by the present claims.

Moreover, no requirement exists for a device or method to address each and every problem sought to be resolved by the present invention, for such to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. However, one skilled in the art should recognize that various changes and modifications in form and material details may be made without departing from the spirit and scope of the inventiveness as set fourth in the appended claims. No claim herein is to be construed under the provisions of 35 U.S.C. § 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”

INDUSTRIAL APPLICABILITY

The present invention relates to a sensor array for a mobile vehicle. More particularly, this invention applies industrially to a sensor array for a mobile vehicle traveling in the Forward direction having a first sensor and a second sensor. The first sensor is mounted to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation. The second sensor is mounted to the mobile vehicle at a maximum lateral distance from said vertical axis of rotation. The first and the second sensor are applied industrially to illuminate objects directly ahead the mobile vehicle and create zones of overlapping beam coverage with other obliquely emitted beams from the mobile vehicle to improve the accuracy of detecting approaching objects. 

1. A sensor array for a mobile vehicle, having a front, a first side, a second side, and a vertical axis of rotation and traveling in a forward direction comprising: a plurality of sensors disposed generally along said front of said mobile vehicle emitting a plurality of object detecting beams, said plurality of sensors including a first sensor disposed at a maximum lateral distance from said vertical axis of rotation near the first side for emitting a first object detecting beam ahead of said mobile vehicle; and a second sensor disposed at a maximum lateral distance from said vertical axis of rotation near the second side for emitting a second object detecting beam ahead of said mobile vehicle.
 2. A sensor array for said mobile vehicle of claim 1, wherein said first sensor and said second sensor mounting further includes recessing at least one of said first sensor and said second sensor within a periphery of said mobile vehicle.
 3. A sensor array for said mobile vehicle of claim 1, further comprising a third sensor, which said third sensor is disposed in said mobile vehicle adjacent to said first sensor, obliquely emits a third object detecting beam that overlaps with said first object detecting beam to create an overlapping beam zone for detecting objects.
 4. A sensor array for said mobile vehicle of claim 3, further comprising a fourth sensor, which said forth sensor is disposed in said mobile vehicle adjacent to said second sensor, obliquely emits a fourth object detecting beam that overlaps with said second object detecting beam to create an overlapping beam zone for detecting objects ahead of said mobile vehicle direction of travel.
 5. A sensor array for said mobile vehicle of claim 4, wherein said overlapping beam zones are computed by sensor fusion software to provide an increased a confidence interval for detecting said object.
 6. A sensor array of claim 1, wherein said first sensor and said second sensor are selected from a group consisting of piezoelectric sensors, electrostatic sensors, magnetorestrictive sensors, infrared sensors and light detecting and ranging (LIDAR) sensors.
 7. A sensor array of claim 1, wherein said first sensor and said second sensor mounting includes positioning said first sensor recessed within a first acoustically tapered matching network and said second sensor recessed within a second acoustically tapered matching network.
 8. A sensor array of claim 7, wherein said first acoustically tapered impedance matching network comprises a first conically tapered horn and said second acoustically tapered impedance matching network comprises a second conically tapered horn.
 9. A sensor array of claim 7, wherein said first acoustically tapered impedance matching network comprises a first conically shaped horn that transitions a small piston diameter acoustical beamwidth radiating from said first sensor and to a larger piston diameter acoustical beam, and said second acoustically tapered impedance matching network which comprises a second conically shaped horn that transitions a small piston diameter acoustical beamwidth radiating from said second sensor to a large diameter acoustical beamwidth.
 10. A sensor array of claim 1, wherein said plurality of sensors are symmetrically spaced-apart sensors that are mounted to said mobile vehicle, wherein symmetrically spaced-apart sensors are located in a same plane.
 11. A sensor array of claim 1, wherein said plurality of sensors are symmetrically spaced-apart sensors that are mounted to said mobile vehicle, wherein symmetrically spaced-apart sensors are located in different planes.
 12. A sensor array of claim 1, wherein said plurality of sensors are asymmetrically spaced-apart sensors that are mounted to said mobile vehicle, wherein asymmetrically spaced-apart sensors are located in a same plane.
 13. A sensor array of claim 1, wherein said plurality of sensors are asymmetrically spaced-apart sensors that are mounted to said mobile vehicle, wherein asymmetrically spaced-apart sensors are located in different planes.
 14. A sensor array as in claims 10, 11, 12, or 13, wherein said symmetrically spaced-apart sensors comprise sonar sensors each emitting a beamwidth within the range of approximately 12 degrees to approximately 15 degrees.
 15. A sensor array as in claims 10, 11, 12, or 13, wherein said symmetrically spaced-apart sensors comprise laser ranging sensors.
 16. A sensor array as in claims 10, 11, 12, or 13, wherein said spaced-apart sensors for said mobile vehicle comprising a rectangular shape with rounded corners are configured in a U-shaped arrangement.
 17. A sensor array as in claims 10, 11, 12, or 13, wherein said spaced-apart sensors for said mobile vehicle are configurable to suit the shape of said front of said mobile vehicle.
 18. A method for controlling a direction of travel of a mobile vehicle having a front, a first side, a second side, a vertical axis of rotation, and traveling in a forward direction comprising: mounting a first sensor to said mobile vehicle at a maximum lateral distance from said vertical axis of rotation near the first side; mounting a second sensor to said mobile vehicle at a maximum lateral distance from said vertical axis of rotation near the second side; emitting a first object detecting beam from said first sensor ahead of said mobile vehicle; emitting a second object detecting beam from said second sensor ahead of said mobile vehicle; and illuminating an object directly ahead of said front of said mobile vehicle.
 19. A method for controlling direction of travel of said mobile vehicle of claim 18, wherein said first sensor and said second sensor mounting further includes recessing at least one of said first sensor and said second sensor within a periphery of said mobile vehicle.
 20. A method for controlling the direction of travel of said mobile vehicle of claim 18, further comprising the steps of: mounting a third sensor to said mobile vehicle along a center of said front of said mobile vehicle; mounting a fourth sensor to said left of said third sensor along said mobile vehicle periphery; emitting an object detecting beam from said fourth sensor, whereby said object detecting beam from said fourth sensor intersects with said object detecting beam from said first sensor to create an first overlapping beam zone; mounting a fifth sensor to said left of said fourth sensor along said mobile vehicle periphery; emitting an object detecting beam from said fifth sensor, whereby said object detecting beam from said fifth sensor intersects with said object detecting beam from said first sensor to create a second overlapping beam zone; and detecting an object ahead at said left forward edge of said mobile vehicle, whereby a confidence interval of increasing value is created depending the number of overlapping beam zones said object is detected within.
 21. A method for controlling the direction of travel of said mobile vehicle of claim 18, further comprising the steps of: collecting data coverage about the location of said object; and processing said data using fusion software.
 22. A method for controlling direction of travel of said mobile vehicle of claim 18, further including the step of mounting spaced-apart sensors along said mobile vehicle to provide more than two overlapping beam zones, wherein said spaced-apart sensors are configurable to provide scanning area coverage selected from a range of approximately 190-degrees to approximately 200-degrees. 